Rework of the Stabilizer Link and Tilt Cylinder Lines{5057, 5104} Caterpillar

Track-Type Tractor:

D8R Series II (S/N: AKA488-946; 6YZ1-1621)

D8R (S/N: 7XM5140-UP; 9EM1337-1919)

Introduction

This special instruction provides procedures to rework the stabilizer links and the corresponding lines on machines that have tubes on top of the link. This procedure is not for machines that have lines that are routed inside the tube of the stabilizer link.

One of the rework procedures will prevent the tilt cylinder lines from becoming pinched in the linkages behind the blade. Another rework procedure in this special instruction will prevent contact between the stabilizer link and the lift cylinders.

Refer to the necessary parts list for ordering parts.

After you complete the procedures, prepare the machine for service. Follow the procedures in the Operation and Maintenance Manual for your machine.

Do not attempt any procedure in this special instruction or order any parts until you have read the information in this special instruction and you understand the information.

Safety

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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

Necessary Parts

Verifying the Alignment of the Stabilizer Link

This procedure will verify the alignment of the bearings on the tube.

Required Tools

Illustration 1	g01013053

Determining the Current Alignment

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Illustration 2	g01013065

1. Use a straight edge and magnetic protractor (A) in order to measure the angle (B) of the bearing. Record angle (B) in Table 3.

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Illustration 3	g01013079

2. Use magnetic protractor (A) and a block on the tube in order to measure angle (C) of the blocks. Record angle (C) in Table 3.
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   Table 3

   	Angle of the Bearing			(B)
   -	Angle of the Blocks	-		(C)
   	Difference			(D)

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Illustration 4	g01014094

3. Subtract "Angle of the Blocks" (C) from "Angle of the Bearing" (B) in order to get "Difference" (D) .

   "Difference" (D) should be 11° ± 2°.

   If "Difference (D) " is not in the tolerance, proceed to ""Modifying the Alignment" ".

   If "Difference (D) " is in the tolerance, proceed to ""Reworking the Stabilizer Link" ".

Modify the Alignment (If Required)

1. Remove all guards, tubes, and hose assemblies from the stabilizer link. Plug hose assemblies. The hose assemblies can remain connected to the manifold on the tractor and the left tilt cylinder, if equipped.

2. Secure the stabilizer link with a suitable lifting device. Remove the stabilizer link from the machine by removing the four bolts, caps, and shims from each end of the link.

   Note: The weight of the stabilizer link is approximately 113 kg (249 lb).

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Illustration 5	g01014072

3. Remove all lugs (E), blocks (F), and blocks (G) from the stabilizer link.

   Note: Be careful not to damage lugs (E) because the lugs will be reused.

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Illustration 6	g01014084
Standard Stabilizer Link (D) 11° ± 2° (E) Lug (H) Do not place a lug in this location. (J) 375 ± 1.5 mm (15.0 ± 0.06 inch) (K) 375 ± 1.5 mm (15.0 ± 0.06 inch) (L) 225 ± 1.5 mm (9.0 ± 0.06 inch) (M) 1168.3 ± 1.5 mm (46.0 ± 0.06 inch) (N) 225 ± 1.5 mm (9.0 ± 0.06 inch) (P) 218.3 ± 1.5 mm (8.60 ± 0.06 inch) (Q) 393.3 ± 1.5 mm (15.48 ± 0.06 inch) (R) 768.3 ± 1.5 mm (30.25 ± 0.06 inch) (S) 968.3 ± 1.5 mm (38.12 ± 0.06 inch) (T) 1453.3 ± 1.5 mm (57.22 ± 0.06 inch) (U) 1718.3 ± 1.5 mm (67.65 ± 0.06 inch) (BB) 483.3 ± 1.5 mm (19 ± 0.06 inch)

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Illustration 7	g01014176
Stabilizer Link for an LGP machine (D) 11° ± 2° (E) Lug (H) Do not place a lug in this location. (J) 375 ± 1.5 mm (15.0 ± 0.06 inch) (K) 375 ± 1.5 mm (15.0 ± 0.06 inch) (L) 225 ± 1.5 mm (9.0 ± 0.06 inch) (N) 225 ± 1.5 mm (9.0 ± 0.06 inch) (V) 740 ± 1.5 mm (29.1 ± 0.06 inch) (W) 370 ± 1.5 mm (14.6 ± 0.06 inch) (X) 245 ± 1.5 mm (9.6 ± 0.06 inch) (Y) 519 ± 1.5 mm (20.4 ± 0.06 inch) (Z) 928 ± 1.5 mm (36.5 ± 0.06 inch) (AA) 1328 ± 1.5 mm (52.3 ± 0.06 inch) (AB) 1850 ± 1.5 mm (72.8 ± 0.06 inch) (AC) 758 ± 1.5 mm (29.8 ± 0.06 inch) (AD) 2010 ± 1.5 mm (79.1 ± 0.06 inch)

4. Relocate eleven lugs (E) at an 11° angle (D). Do not place a lug at location (H). See Illustration 6 and Illustration 7.

5. Proceed to Step 6 of ""Reworking the Stabilizer Link" ".

Reworking the Stabilizer Link

Note: The stabilizer link may remain on the machine for the following procedure.

Procedure

Note: Most of the graphics in the following procedure reference a standard single tilt machine. The LGP machines only differ in the length of the tubes, the stabilizer link, and the locations of the lugs.

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Illustration 8	g01013140

1. Remove the three guards (AE), (AF), and (AG) from the top of stabilizer link.

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Illustration 9	g01014303

2. Remove the right tilt cylinder guard.

3. Disconnect four hose assemblies (AI) and (AJ) from tubes (AH). Plug left hose assemblies (AI) .

4. Remove hose assemblies (AJ) from the right tilt cylinder. Plug the ports on the tilt cylinder. Hose assemblies (AJ) will be replaced in a later step.

   Note: If you have a dual tilt machine, also remove the hose assemblies from the top tubes on the stabilizer link for the left tilt cylinder.

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Illustration 10	g01013163

5. Remove clamps (AK) and tubes (AH) .

   Note: If you have a dual tilt machine, also remove the clamps and tubes that are associated with the left tilt cylinder. The tubes for the left tilt cylinder will not be modified in this procedure.

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Illustration 11	g01013131
The length (AL) for a standard machine is 1311 mm (51.6 inch). The length (AL) for an LGP machine is1568 mm (61.7 inch).

6. Refer to Illustration 11 and the following steps in order to modify tubes (AH) for the right tilt cylinder.

   1. Shorten each tube (AH) by 50 mm (2.0 inch) in order to achieve length (AL) .

      Note: Length (AL) is NOT to the ends of the tubing. Refer to Illustration 11.

   2. Weld flange (1) to the open end of the tubes. Refer to Illustration 11 for additional dimensions and for the orientation of the flange.

   3. Ensure that the tubes are cleaned of debris and plug the tubes.

7. If the stabilizer link is on the machine, use a suitable means to protect the lift cylinders from grinding and welding.

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Illustration 12	g01013165

8. If single lug (E) and three blocks (G) from Illustration 12 have not been removed, mark the location of blocks (G). Remove lug (E) and blocks (G) from the stabilizer link.

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Illustration 13	g01013224
Tube Assembly from a Standard Machine (AM) 1060 mm (41.7 inch) (AN) 485 mm (19.09 inch) (AO) 127 mm (5.0 inch)

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Illustration 14	g01014555
Tube Assembly from an LGP Machine (AP) 1331 mm (52.4 inch) (AQ) 809 mm (31.9 inch) (AR) 409 mm (16.1 inch) (AS) 143 mm (5.6 inch)

9. Assemble clamps, blocks (2), and tubes (AH). Refer to Illustrations 13 and 14. Refer to Illustrations 6 and 7 in order to locate the assembly on the stabilizer link.

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Illustration 15	g01016486
(AT) 75 ± 2 mm (3.0 ± 0.1 inch)

10. Find the center point of the bearings on both ends of the stabilizer link. Measure the bearing at the mating face in order to find the center point.

11. Snap a chalk line between the center points that were found in Step 10. The chalk line should appear to be on the top of the stabilizer link when the sides of the bearings are vertical.

12. In order to find the radial location of the tube mounting blocks and the center guard mounting blocks, measure from the chalk line in the direction of the blade by a distance of 12.76 mm (0.500 inch). Tack weld the tube assembly to the link at this location. Use the dimensions in Illustration 6 and Illustration 7 in order to locate the tube mounting blocks along the length of the stabilizer link. In Illustration 15, the bolt holes of the mounting blocks for the tubes are the center line for the tube assemblies and the guards.

13. Remove clamps and tubes (AH) from blocks (2) .

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Illustration 16	g01014391

14. If blocks (F) have not been removed, scribe the location of the blocks. Then remove the blocks from the stabilizer link. Replace the blocks with blocks (3). Use Illustration 15 and the dimensions in Illustrations 6 and 7 to locate blocks (3). Blocks (3) should be located in line with the center hole of the tube mounting blocks (2) .

    Note: A standard machine requires two blocks (3). An LGP machine requires three blocks (3) .

    Note: If you performed ""Modifying the Alignment" ", ensure that blocks (3) are located at an 11° angle with respect to the bearings.

15. If the procedure in ""Modify the Alignment (If Required)" " was not performed, you should skip this Step. Mount the center guard to the mounting blocks (3). Bolt lugs (E) to the left and right guards. Use the dimensions in Illustration 6 and Illustration 7 in order to locate the positions of the lugs along the stabilizer link. Radially, the left and right guards should be flush with the center guard. Tack weld all of lugs (E) .

16. Trial mount all of the guards and the tube assembly. Finish weld all of the blocks and lugs if no problems are found during the trial mount.

17. Position the modified tubes (AH) on blocks (2). Refer to Illustration 13 or 14 for the proper location.

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Illustration 17	g01013231
Guard (AG) (AV) 70 mm (2.8 inch) (AW) 150 mm (5.9 inch) (AX) 425 mm (16.7 inch)

18. Cut guard (AG) for the right stabilizer link. Refer to Illustration 17 for dimensions.

    Note: The same dimensions are applicable to a guard on a dual tilt machine.

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Illustration 18	g01013254
(AZ) 874 ± 5 mm (34.4094 ± 0.1969 inch) (BA) 26° ± 3°

19. Manufacture two hose assemblies by using (4A), (4B), and (4C). Use wire guards (AY) from existing hose assemblies (AJ). Cut hose (4A) to a length of 760 mm (30 inch). Ensure that the hose assemblies are clean of debris.

    Discard hose assemblies (AJ) .

    Note: The new hose will not look like the old hose.

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Illustration 19	g01014446
(4) Hose (AH) Tubes

20. Reinstall all tubes and hose assemblies with new seals (5). Ensure that the couplings on hose assemblies (4) direct the hose assemblies toward the rear of the machine. Refer to Illustration 19 for the proper orientation.

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Illustration 20	g01035578
(BC) 20 mm (0.79 inch) (BD) Radius (Same size as Original Radius)

21. Trim the guard for the right tilt cylinder. See Illustration 20. Install the guard.

22. Reinstall guards (AE), (AF), and (AG). Install the tilt cylinder guard. Prepare the machine for service.

23. Operate the blade in all ranges of motion. Check for any interferences. If necessary, reposition the hoses in order to eliminate any interference.